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Abstract:

A packaging system and a method of packaging a plurality of floor panels
in a box includes floor panels having a top layer and a bottom layer. The
top layer has a top surface with a visible decorative pattern and a
bottom surface adhered to a top surface of the bottom layer such that the
bottom layer is offset from the top layer in a direction of length and
width and a marginal end portion of the top surface of the bottom layer
and a marginal end portion of the bottom surface of the top layer is
exposed. At least one of the marginal end portions has an adhesive. The
floor panels are stacked in the box in pairs. Each of the pairs is
stacked such that the top surfaces of the top layers of each of the pairs
of the floor panels are facing each other.

Claims:

1. A packaging system, comprising:a plurality of floor panels, each of the
floor panels comprising a top layer and a bottom layer, the top layer
having a top surface with a visible decorative pattern and a bottom
surface adhered to a top surface of the bottom layer such that the bottom
layer is offset from the top layer in a direction of length and width and
a marginal end portion of the top surface of the bottom layer and a
marginal end portion of the bottom surface of the top layer is exposed,
at least one of the marginal end portions having an adhesive; anda box
containing the plurality of floor panels, the floor panels being stacked
in the box in pairs, each of the pairs being stacked such that the top
surface of the top layers of each of the pairs of the floor panels are
facing each other.

2. The packaging system of claim 1, further comprising a support, the
support provided with a plurality of folds and openings, the folds being
positioned in a space that is adjacent the top surfaces of the top layers
of each of the pairs so that the openings receive the marginal end
portions of the bottom layers of one of each of the adjacent pairs.

3. The packaging system of claim 1, wherein the box includes a top panel,
a bottom panel, a first side panel, a second side panel, and bottom end
panels wherein when the box is in a closed position the top panel opposes
the bottom panel, the first side panel opposes the second side panel, and
the bottom end panels oppose each other, and an insert is positioned
adjacent to and extends substantially parallel to at least one of the
first side panel, the second side panel, or the bottom end panels.

4. The packaging system of claim 1, further comprising corner supports
provided in opposing corners of the box.

5. The packaging system of claim 1, wherein each of the floor panels
further comprises a release member adjacent the adhesive.

6. The packaging system of claim 1, wherein the marginal end portions are
substantially L-shaped.

7. The packaging system of claim 1, wherein the top layer comprises a mix
layer.

8. The packaging system of claim 1, wherein the bottom layer is a film or
tape comprising plastic, vinyl, polyvinyl chloride, polyester,
polyolefin, or nylon.

9. The packaging system of claim 1, wherein the bottom layer has a
thickness less than a thickness of the top layer.

10. The packaging system of claim 1, wherein a ratio of a thickness of the
top layer to a thickness of the bottom layer is about 5 or greater.

11. The packaging system of claim 10, wherein the ratio of the thickness
of the top layer to the thickness of the bottom layer is about 10-100.

12. The packaging system of claim 11, wherein the ratio of the thickness
of the top layer to the thickness of the bottom layer is about 10-25.

13. A method of packaging a plurality of floor panels in a box,
comprising:providing a plurality of floor panels, each of the floor
panels comprising a top layer and a bottom layer, the top layer having a
top surface with a visible decorative pattern and a bottom surface
adhered to a top surface of the bottom layer such that the bottom layer
is offset from the top layer in a direction of length and width and a
marginal end portion of the top surface of the bottom layer and a
marginal end portion of the bottom surface of the top layer is exposed,
at least one of the marginal end portions having an adhesive; andstacking
the floor panels in the box in pairs, each of the pairs being stacked
such that the top surface of the top layers of each of the pairs of the
floor panels are facing each other.

14. The method of claim 13, further comprising inserting a support between
the pairs of floor panels, the support having a plurality of folds and
openings, the folds being positioned in a space that is adjacent the top
surfaces of the top layers of each of the pairs so that the openings
receive the marginal end portions of the bottom layers of one of each of
the adjacent pairs.

15. The method of claim 13, wherein the box includes a top panel, a bottom
panel, a first side panel, a second side panel, and bottom end panels
wherein when the box is in a closed position the top panel opposes the
bottom panel, the first side panel opposes the second side panel, and the
bottom end panels oppose each other, and an insert is positioned adjacent
to and extends substantially parallel to at least one of the first side
panel, the second side panel, or the bottom end panels.

16. The method of claim 13, further comprising inserting corner supports
in opposing corners of the box.

17. The method of claim 13, wherein each of the floor panels further
comprises a release member adjacent the adhesive.

18. The method of claim 13, wherein the marginal end portions are
substantially L-shaped.

19. The method of claim 13, wherein the top layer comprises a mix layer.

20. The method of claim 13, wherein the bottom layer is a film or tape
comprising plastic, vinyl, polyvinyl chloride, polyester, polyolefin, or
nylon.

21. The method of claim 13, wherein the bottom layer has a thickness less
than a thickness of the top layer.

22. The method of claim 13, wherein a ratio of a thickness of the top
layer to a thickness of the bottom layer is about 5 or greater.

23. The method of claim 22, wherein the ratio of the thickness of the top
layer to the thickness of the bottom layer is about 10-100.

24. The method of claim 23, wherein the ratio of the thickness of the top
layer to the thickness of the bottom layer is about 10-25.

[0002]The present invention relates to a packaging system for a floor
panel, wherein the floor panel comprises a top layer and a bottom layer
adhered together in an offset relationship such that a marginal end
portion of a top surface of the bottom layer and a marginal end portion
of a bottom surface of the top layer are exposed.

BACKGROUND OF THE INVENTION

[0003]Floor panels for use in floating floor systems typically comprise a
top layer and a bottom layer adhered together in an offset relationship
such that a substantially L-shaped marginal end portion of a top surface
of the bottom layer and a substantially L-shaped marginal end portion of
a bottom surface of the top layer are exposed. The top layer typically
comprises at least one mix layer, a print film, a wear layer, and a top
coat. The bottom layer typically comprises at least one mix layer. The
bottom layer has a thickness about equal to or greater than the top
layer. A ratio of a thickness of the top layer to a thickness of the
bottom layer is typically in the range of about 2 or less. For example,
the SURFACE SOURCE product sold by Lowe's Home Centers, Inc. has a top
layer with a thickness of about 64 mils (about 1.63 millimeters), and a
bottom layer with a thickness of about 61 mils (about 1.55 millimeters).
Thus, the ratio of the thickness of the top layer to the bottom layer is
about 1.05 (64 mils /61 mils=1.05).

[0004]In order to assemble the floating floor system, at least one of the
marginal end portions of each of the floor panels is provided with an
adhesive. The marginal end portion provided with the adhesive is engaged
with the marginal end portion of an adjacent floor panel to form the
floating floor system. The floor panels may be formed, for example, such
that when the floating floor system is assembled on a sub-floor ends of
the top layers of the adjacent floor panels substantially abut, while
ends of the bottom layers of the adjacent floor panels are spaced apart a
desired distance so that a gap is formed there between. Alternatively,
the floor panels may be formed, for example, such that when the floating
floor system is assembled on the sub-floor the ends of the top layers of
the adjacent floor panels substantially abut and the ends of the bottom
layers of the adjacent floor panels substantially abut

[0005]Because the thickness of the bottom layer is significantly large
(about 98 mils (about 2.5 millimeters)), when the floor panels are
assembled such that a gap is formed between the ends of the bottom layers
of the adjacent floor panels, the gap can telescope through the floor
panels thereby significantly altering the aesthetic and structural
characteristics of the top layer. For example, the gaps may cause
buckling at a top surface of the top layer. Alternatively, when the floor
panels are assembled such that the ends of the bottom layers of the
adjacent floor panels substantially abut, unwanted gaps or overlapping
can occur between the ends of the bottom layers due to deviations in the
size of the marginal end portions and/or errors occurring during
installation. These unwanted gaps or overlaps can additionally telescope
through the floor panel thereby also significantly altering the aesthetic
and structural characteristics of the top layer.

[0006]Additionally, the marginal end portions of the top layer of a first
row of the floor panels, which are typically positioned adjacent a wall,
remain unsupported when the floating floor system is assembled, because
the marginal end portions of the top layer of the first row of the floor
panels will not engage with an adjacent floor panel. Thus, because the
thickness of the bottom layer is significantly large, the gap occurring
between the sub-floor and the marginal end portion of the top layer will
also negatively impact the aesthetic and structural characteristics of
the top layer. For example, buckling at the top surface of the top layer
can occur. Also, because the bottom layer and the top layer comprise mix
layers, which contain fillers, the bottom layer and the top layer are
prone to absorb moisture thereby further affecting the aesthetic and
structural characteristics of the floor panels. This is particularly
problematic, since the bottom layer is installed directly on a sub-floor.

[0007]Still further, because the bottom layer has a thickness greater than
the top layer, when the floor panels are stacked, for example, during
shipping, a space exists between the marginal end portions of the top
layer of the adjacent flooring panels equal to the thickness of the
bottom layer. Thus, during shipping, the unsupported marginal end
portions of the top layer are prone to bend and/or curl an amount equal
to the thickness of the bottom layer. Because of the structural
characteristics of the top layer, these bends and/or curls remain in the
marginal end portions of the top layer during installation and can
thereby significantly alter the aesthetic and structural characteristics
of the floor panel. For example, buckling can occur at the top surface of
the top layer and/or the bond strength between the marginal end portions
of the adjacent floor panels could be negatively affected.

[0008]In view of the foregoing, there still remains a need to develop a
floor panel that overcomes the above-described problems. Additionally,
there still remains a need to develop a packaging system and a method for
packaging the floor panels to prevent damage to the floor panels during
shipping.

BRIEF SUMMARY OF THE INVENTION

[0009]A packaging system and a method of packaging a plurality of floor
panels in a box includes floor panels having a top layer and a bottom
layer. The top layer has a top surface with a visible decorative pattern
and a bottom surface adhered to a top surface of the bottom layer such
that the bottom layer is offset from the top layer in a direction of
length and width and a marginal end portion of the top surface of the
bottom layer and a marginal end portion of the bottom surface of the top
layer is exposed. At least one of the marginal end portions has an
adhesive. The floor panels are stacked in the box in pairs. Each of the
pairs is stacked such that the top surfaces of the top layers of each of
the pairs of the floor panels are facing each other.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a perspective view of a floor panel according to an
embodiment of the invention.

[0011]FIG. 2 is a perspective view of a box of shown in an open position.

[0012]FIG. 3 is a perspective view of a plurality of the floor panels
stacked in the box.

[0013]FIG. 4 is a perspective view of a support inserted in-between the
floor panels stacked in the box.

[0014]FIG. 5 is a perspective view of the box in a partial closed
position.

[0015]FIG. 6 is a perspective view of the box in a partial closed
position.

[0016]FIG. 7 is a perspective view of an insert provided in the box.

[0017]FIG. 8 is a perspective view of the box in a closed position.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

[0018]FIGS. 1-3 show a floor panel 10 according to a first embodiment of
the invention. As shown in FIG. 1, the floor panel 10 comprises a top
layer 11, a bottom layer 12, and a release member 13. The top layer 11
may be formed, for example, from a substantially flexible sheet material,
such as plastic, vinyl, polyvinyl chloride, polyester, or combinations
thereof. The top layer 11 has a top surface 14 with a visible decorative
pattern 17 and a bottom surface 15. In the illustrated embodiment, the
top layer 11 comprises at least one mix layer 16, a print film provided
with the visible decorative pattern 17, a wear layer (not shown), and a
top coat (not shown), respectively. It will be appreciated by those
skilled in the art that although the top layer 11 is shown and described
herein as comprising multiple layers that the top layer 11 may
alternatively comprise a single layer. Additionally, the types of layers
constituting the top layer 11 and the visible decorative pattern 17 could
be varied depending on the desired characteristics of the top layer 11.

[0019]As shown in FIG. 1, the top layer 11 has a thickness T1 of about
20-200 mils (about 0.508-5.08 millimeters), preferably about 60-180 mils
(about 1.524-4.572 millimeters), and more preferably about 80-150 mils
(about 2.032-3.810 millimeters). In the illustrated embodiment, the top
layer 11 is substantially rectangular in shape and has a length L1 of
about 36 inches (about 91.4 centimeters) and a width W1 of about 6 inches
(about 15.2 centimeters). However, it will be appreciated by those
skilled in the art that the geometrical shape and the length L1 and the
width W1 of the top layer 11 may be varied depending on the desired
dimension and geometrical configuration of the floor panel 10. For
example, the top layer 11 may alternatively have a substantially square
shape.

[0020]As shown in FIG. 1, the bottom layer 12 has a top surface 18 and a
bottom surface 19. The bottom layer 12 may be formed, for example, from a
film or tape comprising plastic, vinyl, polyvinyl chloride, polyester,
polyolefin, nylon, or combinations thereof. The bottom layer 12 may also
include recycle material, such as post industrial or post consumer scrap.
The film or tape may be rigid or flexible and is preferably moisture
resistant or waterproof. Additionally, the film or tape may be capable of
being delivered or shipped in a roll. In the illustrated embodiment, the
bottom layer 12 comprises a single layer of rigid black polyvinyl
chloride film. Alternatively, the bottom layer 12 could comprise multiple
layers, such as two layers of film laminated with a mat, such as a glass
mat or polyethylene terephthalate mat, there between. The bottom layer 12
could also be provided with at least one of a continuous or discontinuous
ink layer, antimicrobial layer, sound deadening layer, cushioning layer,
slide resistant layer, stiffening layer, channeling layer, mechanically
embossed texture, or chemical texture.

[0021]As shown in FIG. 1, the bottom layer 12 has a thickness T2 less than
the thickness T1 of the top layer 11. The thickness T2 of the bottom
layer 12 is, for example, about 1-60 mils (about 0.0254-1.524
millimeters), preferably about 6.5-12 mils (about 0.1651-0.3048
millimeters), and more preferably about 8 mils (about 0.2032
millimeters). A ratio of the thickness T1 of the top layer 11 to the
thickness T2 of the bottom layer 12 is about 5 or greater, preferably
about 10-100, and more preferably about 10-25. The bottom layer 12 has a
length L2 and a width W2 the same as the length L1 and the width W1 of
the top layer 11. Thus, in the illustrated embodiment, the bottom layer
12 is substantially rectangular in shape and has the length L2 of about
36 inches (about 91.4 centimeters) and the width W2 of about 6 inches
(about 15.2 centimeters). However, it will be appreciated by those
skilled in the art that the geometrical shape and the length L1 and the
width W1 of the bottom layer 12 may be varied depending on the desired
dimension and geometrical configuration of the floor panel 10. For
example, the bottom layer 12 may alternatively have a substantially
square shape.

[0022]As shown in FIG. 1, the bottom surface 15 of the top layer 11 is
laminated to the top surface 18 of the bottom layer 12 by an adhesive 20.
The adhesive 20 may be, for example, any suitable adhesive, such as a hot
melt adhesive, a pressure sensitive adhesive, or a structural and/or
reactive adhesive. In the illustrated embodiment, the adhesive is a
pressure sensitive acrylic adhesive. The adhesive 20 may have, for
example, a bond strength of at least 25 force-pounds, and more preferably
about 25-30 force-pounds after having been heat aged for about 24 hours
at 145 degrees Fahrenheit. In the illustrated embodiment, the adhesive 20
is provided on substantially an entirety of the top surface 18 of the
bottom layer 12. The adhesive 20 may be applied to have a thickness, for
example, of about 1-2 mils (about 0.0254-0.0508 millimeters). It will be
appreciated by those skilled in the art, however, that the thickness of
the adhesive 20 may vary depending on the texture of the bottom surface
15 of the top layer 11 and the texture of the top surface 18 of the
bottom layer 12 in that a substantially smooth surface would require less
of the adhesive 20 due to better adhesion and bond strength.

[0023]The top layer 11 is adhered to the bottom layer 12 so that the top
layer 11 is offset from the bottom layer 12 in a direction of the length
L1, L2 and the width W1, W2. In other words, opposing first ends 21 of
the top layer 11 are offset in the direction of the length L1, L2 from
opposing first ends 23 of the bottom layer 12 an offset distance D1, D2
and opposing second ends 22 of the top layer 11 are offset in the
direction of the width W1, W2 from opposing second ends 24 of the bottom
layer 12 an offset distance D3, D4. The offset distances D1, D2, D3, D4
are substantially the same. In the illustrated embodiment, the offset
distances D1, D2, D3, D4 are, for example, about 1 inch (about 2.5
centimeters). It will be appreciated by those skilled in the art,
however, that the offset distances D1, D2, D3, D4 may be varied depending
on the desired configuration of the floor panel 11. Examples of possible
variations in the offset distances D1, D2, D3, D4 are set forth, for
example, in U.S. patent application Ser. No. 12/412,419, filed Mar. 27,
2009, which is hereby incorporated by reference in its entirety. Because
the adhesive 20 is provided on substantially the entirety of the top
surface 18 of the bottom layer 12, due to the offset of the top layer 11
relative to the bottom layer 12, a substantially L-shaped marginal end
portion of the top surface 18 of the bottom layer 12 remains exposed to
form an adhesive surface 25, and a substantially L-shaped marginal end
portion of the bottom surface 15 of the top layer 11 remains exposed to
form an attachment surface 26.

[0024]It will be appreciated by those skilled in the art that the adhesive
20 may also be provided on the marginal end portion of the bottom surface
15 of the top layer 11 instead of or in addition to the top surface 18 of
the bottom layer 12 depending on the type and characteristics of the
adhesive 20 used to achieve optimum adhesion and bond strength when
adhering the adjacent floor panels 10, as described in more detail below
with reference to FIGS. 2-3. Further, the adhesive 20 used to adhere the
top layer 11 to the bottom layer 12 may be different from the adhesive 20
provided on the marginal end portions of the top layer 11 and and/or the
bottom layer 12.

[0025]As shown in FIG. 1, the release member 13 is positioned adjacent to
the top surface 14 of the top layer 11 and the adhesive surface 25 to
cover the adhesive surface 25 during shipping of the floor panel 10 and
prior to the installation thereof. In the illustrated embodiment, the
release member 13 is a flexible sheet corresponding in size and shape to
the bottom layer 12. It will be appreciated by those skilled in the art,
however, that the size and shape of the release member 13 may be varied,
as long as the release member 13 adequately covers the adhesive surface
25. For example, the release member 13 could just correspond in size and
shape to the substantially L-shaped marginal end portion of the top
surface 18 of the bottom layer 12. The release member 13 may be made, for
example, from any known suitable release material, such as a poly or
silicone coated paper, a plastic sheet, a polymer film, or other material
that enables the release member 13 to be quickly and easily removed from
the adhesive surface 25 during the installation of the floor panel 10.
The release member 13 may additionally be provided with a tab (not shown)
that extends from the release member 13 in order to increase the ease of
removal of the release member 13 from the adhesive surface 25 during the
installation of the floor panel 10.

[0026]A packaging system for the floor panel 10 will now be described in
greater detail with reference to FIGS. 2-7. As shown in FIG. 2, the
packaging system comprises a substantially rectangular box 30. The box 30
consists of a consecutive attachment of a first side panel 31, a bottom
panel 32, a second side panel 33, a top panel 34, and an attachment panel
35. Bottom end panels 36 extend from opposing ends of the bottom panel
32. Top end panels 37 extend from opposing ends of the top panel 34. Tabs
38 extending from opposing ends of the first and second side panels 31,
33. Tabs (not shown) may also optionally extend from opposing ends of the
attachment panel 35. Notches 50 are provided in opposing ends of each of
the tabs 38. Projections 41 extend from end surfaces of the first side
panel 31 and the bottom end panels 36. The projections 41 correspond to
projection receiving openings 42 formed in the bottom panel 32.

[0027]The first side panel 31, the bottom panel 32, the second side panel
33, the top panel 34, and the attachment panel 35 have a length
substantially corresponding to a total length of the floor panel 10,
wherein the total length of the floor panel 10 is about equal to the
length L2 of the bottom layer 12 plus the offset distance D2 of the top
layer 11. The bottom panel 32 and the top panel 34 have a width
substantially corresponding to a total width of the floor panel 10,
wherein the total width of the floor panel 10 is about equal to the width
W2 of the bottom layer 12 plus the offset distance D4 of the top layer
11.

[0028]A first crease 41 is provided in an approximately a center of the
first side panel 31. A second crease 42 is provided between the first
side panel 31 and the bottom panel 32. A third crease 43 is provided
between the bottom panel 32 and the second side panel 33. A fourth crease
44 is provided between the second side panel 33 and the top panel 34. A
fifth crease 45 is provided between the top panel 34 and the attachment
panel 35. Sixth creases 46 are provided in an approximate center of each
of the bottom end panels 36. Seventh creases 47 are provided between each
of the bottom end panels 36 and the bottom panel 32. Eighth creases 48
are provided between each of the tabs 38 and the first and second side
panels 31, 33. Ninth creases 49 are provided between each of the top end
panels 37 and the top panel 34.

[0029]As shown in FIG. 3, a plurality of the floor panels 10 is stacked on
the bottom panel 32 of the box 30. The floor panels 10 are stacked in
pairs 51. Each of the pairs 51 is stacked such that the top surface 14 of
the top layers 11 of each of the pairs 51 of the floor panels 10 are
facing each other. Additionally, the floor panels 10 are all stacked in
the same direction so that the unsupported marginal end portions of the
bottom layer 12 provided with the release paper 13 that covers the
adhesive surface 25 are positioned adjacent to each other.

[0030]As shown in FIG. 4, at least one support 52 may optionally be
provided to additionally support and prevent damage to the unsupported
marginal end portions of the bottom layers 12. The support 52 has a
substantially accordion-like profile and is provided with a plurality of
folds 53 that form a plurality of opposing substantially v-shaped
openings 54. Each of the folds 53 is inserted in a space formed adjacent
the abutting top surfaces 14 of the top layers 11 of each of the pairs 51
so that the openings 54 receive the unsupported marginal end portions of
the bottom layers 12 of one of each of the adjacent pairs 51. The
supports 52 may be provided, for example, at several positions along the
side of the stack of the floor panels 10 with the unsupported marginal
end portions of the bottom layers 12.

[0031]As shown in FIG. 5, after the floor panels 10 are stacked on the
bottom panel 32, and the supports 52 are optional provided on the floor
panels 10, the box 30 is partially closed. In order to partially close
the box 30, the bottom end panels 36 are folded about the sixth creases
46, and the projections 39 of the bottom end panels 36 are inserted into
the projection receiving openings 40 in the bottom panel 32.
Simultaneously, the bottom end panels 36 are folded about the seventh
creases 47 toward the floor panels 10. The first side panel 31 is folded
about the first crease 41, and the projections 39 of the first side panel
31 are inserted into the projection receiving openings 40 in the bottom
panel 32. Simultaneously, the first side panel 31 is folded about the
second crease 42 toward the floor panels 10, and the tabs 38 of the first
side panel 31 are folded inward about the eighth creases 48 and inserted
into the bottom end panels 36. The second side panel 33 is folded about
the third crease 43 toward the floor panels 10, and the tabs 38 of the
second side panel 33 are folded inward about the eighth creases 48 and
inserted into the bottom end panels 36. The top panel 34 is then folded
about the fourth crease 44.

[0032]As shown in FIGS. 5-6, before or after the box 30 is partially
closed, corner supports 55 may be provided in the box 30. The corner
supports 55 are substantially rectangular blocks, may be solid or hollow,
and may be formed, for example from plastic, cardboard, styrofoam, wood,
or other similar material. Although the supports 55 are shown and
described herein as being separate pieces from the box 30, it will be
appreciated by those skilled in the art that the supports 55 may
alternatively be integrally formed with the box 30. The supports 55 are
provided in the empty spaces in at least one corner of the box 30 and
preferably two opposing corners of the box 30 to further stabilize the
floor panels 10 therein. It will be appreciated by those skilled in the
art, however, that additional supports 55 may be provided, as necessary,
to further stabilize the floor panels 10 in the box 30.

[0033]As shown in FIG. 7, an insert 56 may optionally be provided to
provide additional support to the first side panel 31, the second side
panel 33, and the bottom end panels 36 of the box 30, thereby further
protecting the floor panels 10 from damage. In the illustrated
embodiment, the insert 56 is positioned adjacent to and extends
substantially parallel to the first side panel 31, the second side panel
33, and the bottom end panels 36 of the box 30. Alternatively, or in
addition, the insert 56 may be sandwiched between opposing sides of the
first side panel 31, which opposing sides are created after folding the
first side panel 31 about the first crease 41, and between opposing sides
of the bottom end panels 36, which opposing sides are created after
folding the bottom end panels 36 about the sixth creases 46. The insert
56 may be formed, for example, from C-flute corrugated cardboard, foam,
or other similar material.

[0034]As shown in FIG. 8, in order to close the box 30, an adhesive (not
shown) is applied to the inner surface of the attachment panel 35 and/or
an outer surface of the first side panel 31. The attachment panel 35 is
folded inward about the fifth crease 45 until the inner surface of the
attachment panel 35 contacts the outer surface of the first side panel 31
thereby adhering the attachment panel 35 to the first side panel 31.
Additionally, if tabs (not shown) are provided on opposing ends of the
attachment panel 35, the tabs (not shown) of the attachment panel 35
would be folded inward and inserted into the first side panel 31 during
the aforementioned folding process. An adhesive (not shown) is also
applied to the inner surface of the top end panels 37 and/or an outer
surface of the bottom end panels 36. The top end panels 27 are folded
inward about the ninth creases 49 until the inner surface of the top end
panels 27 contact the outer surface of the bottom end panels 36 thereby
adhering the top end panels 27 to the bottom end panels 36. The box 30 is
thereby closed. The packaging system as provided herein not only
adequately protects and supports the floor panels 10, but also prevents
damage to the unsupported marginal end portions of the bottom layers 12
during shipping.

[0035]The foregoing illustrates some of the possibilities for practicing
the invention. Many other embodiments are possible within the scope and
spirit of the invention. It is, therefore, intended that the foregoing
description be regarded as illustrative rather than limiting, and that
the scope of the invention is given by the appended claims together with
their full range of equivalents.